Corrugated aluminum foil board

ABSTRACT

A corrugated aluminum foil board has one or more sheets of aluminum foil corrugated, ridged, or bent in a wave-like or folded pattern to achieve increased rigidity, and sandwiched between aluminum foil sheets to form a strong and rigid material composition resembling metallic cardboard. The shaped sheets may be assembled by using a non-flammable glue, or by welding or otherwise fastened or fused, to create a generally rigid, lightweight, and fire resistant material with many advantages for the entertainment industry with respect to motion picture or television lighting, and other uses.

RELATED APPLICATION INFORMATION

This application is a continuation of U.S. application Ser. No.12/344,201, filed Dec. 24, 2008, which claims the benefit of U.S.Provisional Application Ser. No. 61/017,048, filed on Dec. 27, 2007,hereby incorporated by reference as if set forth fully herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The field of the present invention generally relates to a sheet materialcomposition and objects manufactured therefrom, such as snoots, flags,bounce boards, light boxes and other devices designed to block, contain,reflect, direct or control light for motion picture or photographic use.

2. Background

In the entertainment industry including motion pictures, television andtheatrical arts, as well as in the photographic industry and otherfields it is necessary to light a set, stage or other area. Often thelight produced from the available instruments needs to be shaped,softened, bounced, contained or controlled to make the most desirablepicture.

Conventional wisdom is to use Fome-cor® extruded polystyrene foam sheetslaminated between two 12-point clay-coated paper liners or othervariations or similar materials (including “poly” polystyrene board) tofashion snoots, flags, bounce boards, light boxes and other devices toattain the desired light modification and control.

These materials have the advantageous properties of an “Art Board”—thatis, easy to cut (e.g., with a razor knife), score, bend and shape. Thesematerials are also rigid and lightweight, with several choices ofthickness and surface combinations (including black and white).

Other products such as fabrics like duvatyne and ultra bounce,commercially manufactured flags, frames with grifflon or lames stretchedon them, aluminum foil sometimes painted or anodized black, and othermethods of controlling/modifying light are also sometimes used in theentertainment industry. Drawbacks of these materials when compared toFome-cor or the like for many purposes include not being rigid,foldable, or easily cut, shaped and formed, or having inappropriateweight, size, etc. The various properties of the foam board aspreviously described makes it well suited for use in the entertainmentfield.

Unfortunately, there is a major flaw in the use of this “Art Board” forlighting in the entertainment industry: the material's flammability. Thematerial appears to combust quite rapidly, which is a serious concern asit is often used in close proximity to hot motion picture lights. Therehave been numerous fires on motion picture and television sets in thepast decade now that use of these materials has become commonplace. Whenheated or burning, these foam board materials can drip hot material andgive off dangerous gases. The structural integrity under heat is also anissue as well as changing form due to being composed of material(s) thatare effected by heat.

Another concern with foam boards is the fact that they arenon-biodegradable, and thus have an adverse impact on the environment.

Recent “flame resistant” foam boards have been made that are designednot to continue to burn where the source of the flame is removed, and toresist ignition and combustion. While addressing the problem of fire isa step in the right direction, utmost safety is not achieved with thesematerials. Cost of these flame resistant foam boards also may besignificantly higher than prior foam boards.

Other attempts to overcome the flammability problem of conventional foamboards involve covering the foam board surfaces with foil. However, thisdoes not necessarily solve the problem of heat-induced warpage orpotential flammability. Also, making custom foil-covered foam boards islabor-intensive and expensive.

What is needed is a product that has the useful properties of the foamboard, including rigidity and lightness in weight, that is easily cut,scored and shaped, with several available thicknesses, yet without thedangerous properties of being made from polystyrene foam and paper whichare both combustible. An ideal material would be, among other things,highly heat and fire resistant, and made from recycled materials and/oritself recyclable.

SUMMARY OF THE INVENTION

In one or more embodiments, a corrugated aluminum foil board is providedthat may find use in the entertainment field to fashion snoots, flags,bounce boards, light boxes, etc., for use in proximity to hot motionpicture or television lights while improving safety greatly throughimproved fire and heat resistance.

In an embodiment, a corrugated aluminum foil board material may bemanufactured of one or more sheets of woven, bent or folded aluminizedmaterial, much like cardboard. An aluminum foil (or other similarsheetlike material) is preferably corrugated or bent in a wave-like orfolded pattern to achieve increased rigidity. One or more sheets of thisshaped material, or materials, may be layered at intersecting orcrossing angles and, if desired, sandwiched between flat foil or othermaterial. The shaped sheets may be assembled by using a non-flammableglue, or by welding or otherwise fastened or fused, to create agenerally rigid, lightweight, and fire resistant material with manyadvantages for the entertainment industry and possibly other uses.

In certain embodiments, the versatility of the corrugated aluminum foilboard may be enhanced by modifying the exposed surface of the board.Different surface colors, patterns and/or materials may be utilized forthe surface, thus modifying the quality and reflection of light and heatin an advantageous way, such as an aluminum surface that could be hardor soft (possibly variegated) silver, gold, blue etc, as well as moreconventional black or white. Various lighting effects can be achieved bytexturing, laminating, dying, painting or anodizing the outer surface(s)of the resulting aluminum foil board. Perforation of the board may beadvantageous in certain applications—for example, to reduce weightand/or allow wind to pass through for outdoor reflector type use. Thefact that the basic material is waterproof and an efficientreflector/absorber/radiator of light/heat energy may allow the resultingfoil board structure to have significant other uses in packaging,fluorescent light housings, model making or other applications.Variations in the direction of the corrugated wafers might also be usedto control rigidity for various applications. It may also beadvantageous to incorporate aluminum (or other) wires to increasestrength or mold ability. Introduction of PVC or other materials may beadvantageous to reduce electrical conductivity, control audibleproperties, or modify other attributes.

It may also be advantageous to make the aluminum foil boardmaterial/product in a form that can “roll up”. For example, by providingridges (or scores) along only one length, it would be possible to rollup the material for shipping or storage. Affixing (e.g., sandwiching)two or more pieces together with the ridges juxtaposed would create arigid and flat “board ” when affixed but a compact rolled up materialwhen not affixed. Such ability to roll up the material could also beadvantageous in creating cylindrical shaped “snoots” for use to shapethe light from a lighting instrument.

An aluminum foil board made according to embodiments as described hereinmay be used, for example, to fashion snoots, flags, bounce boards, lightboxes and other devices needing a lightweight, rigid, easily cut andshaped fire-resistant material to block, contain, reflect, direct orcontrol light for motion picture or photographic use.

Further variations, modifications and enhancements are also describedherein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a diagram of a partial cutaway front view of a corrugatedaluminum foil board in accordance with one embodiment as disclosedherein, and FIG. 1B is a cross sectional side view of the same.

FIG. 2A is a diagram of a partial cutaway front view of a corrugatedaluminum foil board in accordance with another embodiment, and FIG. 2Bis a cross sectional side view of the same.

FIG. 3 is a diagram showing different surface textures or variations ofan aluminum foil board.

FIG. 4 is a diagram of a partial cutaway view of an aluminum foil boardpair showing corrugation in one direction (or slit) so that it isrollable, with the two foil boards being fastenable at juxtaposed anglesto create rigidity. Different surfaces are shown to illustrate use as avariable surface reflector.

FIG. 5A is a side view diagram of an aluminum foil board that has beenrolled into a more compact size.

FIG. 5B is a side view diagram of an aluminum foil board that has beenrolled into the shape of a snoot, and FIG. 5C shows the rolled snoot ofFIG. 5B attached to a lighting fixture.

FIGS. 6A and 6B are side and front view diagrams, respectively, showinga generally box-shaped snoot fashioned from a rigid aluminum foil boardand attached to a yoke-mounted multi-light lighting fixture.

FIG. 7 is an oblique diagram showing further details of a centralaluminum sheet core as may be used in various embodiments of an aluminumfoil board.

FIGS. 8A and 8B are oblique view diagrams showing a corrugated aluminumfoil board with smooth side sheets and variegated side sheets,respectively.

FIG. 9 is a diagram of a reinforced aluminum sheet as may be used in analuminum foil board in various embodiments.

FIG. 10 is a diagram of an aluminum sheet with air-filled aluminumbubbles as may be used in an aluminum foil board in various embodiments.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1A is a diagram of a partial cutaway front view of a corrugatedaluminum foil board 100 in accordance with one embodiment as disclosedherein, and FIG. 1B is a cross sectional side view of the same.

In FIG. 1A, the corrugated aluminum foil board 100 comprises a firstoutside layer 101 of flat aluminum foil, a middle layer 105 ofcorrugated, bent or folded aluminum foil, and a second outer layer 109of flat aluminum foil, arranged such that the middle layer 105 issandwiched between the first outside layer 101 and second outside layer109 of aluminum foil. The outside layers 101, 109 may be affixed to themiddle layer 105 by welding, heat-resistant adhesive, or other means.The middle layer 105 is preferably corrugated, similar to cardboard, orelse woven, bent or otherwise folded in a wave-like or other pattern toachieve increased rigidity. FIG. 1B shows a side view of the aluminumfoil board 100. The middle layer 105 may include one or more sheets ofaluminum foil material. The inventor has found that despite the relativeflimsiness of aluminum foil, when the foil is corrugated (as the middlelayer 105) and sandwiched between two foil sheets (as outside layers101, 109), the resulting structure is surprisingly and unexpectedlyrigid and firm, and capable of self-support. The aluminum foil board 100resulting from this structure forms a generally rigid, lightweight, andfire resistant composite structure that may be shaped or rolled, withmany advantages for use as lighting fixture accessories or for otherapplications.

The pattern of corrugations, folds, creases or other similar features inthe central aluminum sheet core is preferably repeating and regular,with a sufficient number of features to provide structural support forthe aluminum foil board. For example, a repeating feature every ½″ to ¾″inch may generally be sufficient to provide the desired structuralsupport for an aluminum foil board in many applications. FIG. 7 is anoblique diagram showing further details of a central aluminum sheet core700 as may be used in various embodiments of an aluminum foil board,such as the aluminum foil board 100 of FIG. 1A. In FIG. 7, an aluminumsheet has been repeatedly folded into a series of overlying folds 703,each having a pair of overhanging creased edges 706. In other examples,the folds 703 may be flattened or flatter as compared to FIG. 7, or maybe double-folded (or more) or else folded to one side, or otherwiseformed into a repeating patterned structure having similar qualities.The term “corrugated” as used herein is intended to encompass variousfolded, ridged, grooved, wave-like or other similar patterns achievingincreased rigidity of the otherwise relatively flimsy foil sheet. Thealuminum foil may be corrugated by any of a number of means, includingpotentially using a corrugating machine similar to those used to makecorrugated cardboard.

The outside sheets of the foil board may also take various forms or havedifferent textures. FIGS. 8A and 8B are oblique view diagrams showing acorrugated aluminum foil board with smooth side sheets and variegatedside sheets, respectively. Thus, in FIG. 8A, the outside layers 801, 809of aluminum foil are both smooth, whereas in FIG. 8B, the outside layers821, 829 of aluminum foil are wavy or slightly crinkled or creased. Thedifferent textures of the outside layers provide a variety of differentoptions for modifying or adjusting illumination from a lighting fixtureon, e.g., a motion picture of television studio set.

FIG. 2A is a diagram of a partial cutaway front view of a corrugatedaluminum foil board 200 in accordance with another embodiment, and FIG.2B is a cross sectional side view of the aluminum foil board 200.

In FIG. 2A, the corrugated aluminum foil board 200 comprises a firstoutside layer 201 of flat aluminum foil, a first middle layer 205 ofcorrugated, bent or folded aluminum foil, a second middle layer 206 ofcorrugated, bent or folded aluminum foil, and a second outer layer 209of flat aluminum foil, arranged such that the middle layers 205, 206 aresandwiched between the first outside layer 201 and the second outsidelayer 209 of flat aluminum foil. The various layers 201, 205, 206 and209 may be affixed to one another by welding, heat-resistant adhesive,or other means. The middle layers 205, 206 may each be corrugated,similar to cardboard, or else woven, bent or otherwise folded in awave-like or other pattern to achieve increased rigidity. The directionof the corrugated pattern for the first middle layer 205 is preferablyperpendicular to the direction of the corrugated pattern for the secondmiddle layer 206, so that the ensuing structure is rigid in bothdirections, and thus making the aluminum foil board 200 of thisembodiment resistant to bending or rolling. FIG. 2B shows a side view ofthe aluminum foil board 200. Each of the middle layers 205, 206 mayinclude one or more sheets of aluminum foil material. The inventor hasfound that despite the relative flimsiness of aluminum foil, when thefoil is corrugated in perpendicular directions (as the middle layers205, 206) and sandwiched between two foil sheets (as outside layers 201,209), the resulting structure is surprisingly and unexpectedly rigid andfirm, even more so than when a single middle layer is used (as in FIG.1A). The aluminum foil board 200 resulting from this structure forms agenerally rigid, lightweight, and fire resistant composite structurethat may be shaped or interconnected into larger shapes (boxes, etc.),with many advantages for use as lighting fixture accessories or forother applications.

FIG. 3 is a diagram showing different surface textures or variations ofan aluminum foil board 300. For example, the aluminum foil board 300 mayinclude a first plurality of sections 301 of a first colorized foil(e.g., gold) having a variegated pattern, bearing perforations, orhaving other textural variations (creases, wrinkles, waves, or thelike), and a second plurality of sections 305 having a second colorizedfoil (e.g., silver) having a smooth or “hard” pattern. The pattern ofsections 301, 305 of the different colored/textured foils may berepeating or symmetrical, as shown in FIG. 3, or else may be asymmetricor random in various respects. For example, the sections 301, 305 may bearranged in a checkerboard pattern. The sections 301, 305 may also be ofthe same size or different sizes. More than two different types,colorations, textures, etc. of foil may be used.

FIG. 4 is a diagram of partial cutaway views of a pair of aluminum foilboards 400, 420 in accordance with another embodiment. In the example ofFIG. 4A, each aluminum foil board 400, 420 may be constructed similar tothe embodiment of FIGS. 1A-1B. That is, the first aluminum foil board400 may comprise a first outside layer 401 of flat aluminum foil, amiddle layer 405 of corrugated, bent or folded aluminum foil, and asecond outer layer 409 of flat aluminum foil, arranged such that themiddle layer 405 is sandwiched between the first outside layer 401 andsecond outside layer 409 of aluminum foil. The second aluminum foilboard 420 may likewise comprise a first outside layer 421 of flataluminum foil, a middle layer 425 of corrugated, bent or folded aluminumfoil, and a second outer layer 429 of flat aluminum foil, arranged suchthat the middle layer 425 is sandwiched between the first outside layer421 and second outside layer 429 of aluminum foil. As with FIG. 1A, theoutside layers 401, 409 or 421, 429 may be affixed to the middle layer405 or 425, respectively, by welding, heat-resistant adhesive, or othermeans.

In the example of FIG. 4, each of the pair of aluminum foil boards 400,420 is provided with a different outer foil material (in terms of color,shape, texture, etc.), so as to provide a variety of reflective surfaceoptions from only two aluminum foil boards 400, 420. For example, thefirst aluminum foil board 400 may have a first outside layer 401 (i.e.,front surface) of aluminum or hard silver (dull), and a second outsidelayer 409 (i.e. back surface) of variegated soft silver. The secondaluminum foil board 420 may have a first outside layer 421 (i.e., frontsurface) of aluminum or hard silver (shiny), and a second outside layer429 (i.e. back surface) of variegated /soft gold. The pair of aluminumfoil boards 400, 420 may be affixed together front-to-back,front-to-front, or back-to-back to create a total of four differentreflective combinations. The aluminum foil boards 400, 420 may beaffixed together by, e.g., duct tape, electrical tape, aluminum foiltape, clips, staples, etc. If affixed together with corrugations in thesame direction, the resulting foam board pair may be rollable orbendable, and if affixed with corrugations in perpendicular directions,the resulting foam board pair would be generally rigid and inflexible.These various options may provide a lighting engineer or technician witha substantial number of options for creating different lighting effectsusing the reflectivity of the desired foam board pairing. Similarly, thealuminum foil board pair may be affixed to create a rigid structure foruse on a set, while taken apart and rolled up for ease of transport orstorage when not in use.

FIG. 5A is a side view diagram of an aluminum foil board 500 that hasbeen rolled into a more compact size.

FIG. 5B is a side view diagram of an aluminum foil board 530 that hasbeen rolled into the shape of a snoot, and FIG. 5C shows the rolledsnoot 530 of FIG. 5B attached to a lighting fixture 535. The aluminumfoil board 530 may be held together at the ends by, e.g., duct tape,electrical tape, aluminum foil tape, clips, staples, etc., thus keepingit in the rolled shape. The rolled aluminum foil board 530 may beattached to the lighting fixture 535 by any suitable means, includingspring clamps, grip clips, binder clips, clothes pins, etc.

FIGS. 6A and 6B are side and front view diagrams, respectively, showinga generally box-shaped snoot 630 fashioned from a rigid aluminum foilboard and attached to a yoke-mounted multi-light lighting fixture 635.In FIGS. 6A and 6B, multiple pieces of aluminum foil board have been cutinto the various sides, top and bottom of the box-shaped snoot 630, andattached using heat resistant adhesive, welding, metal clips, wirerings, staples, or other means such as duct tape, electrical tape,aluminum foil tape, etc. In this example, the aluminum foil boards arepreferably rigid in nature, constructed in accordance with theembodiment of FIG. 2A. The resulting box-shaped snoot 630 provided anon-flammable, lightweight, maneuverable and versatile lighting controlmechanism, for directing and channeling light from the lighting fixture635, as well as creating various effects due to different possiblereflective surfaces that can be used to construct the aluminum foilboard that forms the sides, bottom and top of the snoot 630.

The material used to create the aluminum foil boards described hereinmay be manufactured much like cardboard. For example, the aluminum foilmay first be corrugated (bent) in a possibly wave (or folded up like afan) type pattern to achieve increased rigidity. One, two or more sheetsof this shaped material (or materials), possibly layered at intersectingor crossing angles, and, if desired, sandwiched between flat foil orother material, create a rigid, lightweight fire resistant material withmany advantages for the entertainment industry and possibly other use.Various surface effects can be achieved by texturing, laminating, dying, painting or anodizing the outer surface(s) of the aluminum foil board.The term “aluminum foil” is meant to include all of the foregoingvariations, as well as alloys made primarily from aluminum but alsocontaining other materials (e.g., tin, copper, magnesium, etc.)Perforation may be advantageous in certain applications to reduce weightand allow wind to pass through for outdoor reflector type use. Thealuminum foil material is generally waterproof and is also an efficientreflector/absorber/radiator of light/heat energy, thus providingsignificant other potential uses in packaging, fluorescent lighthousings, model making or other applications. Variations in thedirection of the corrugated wafers can be used to control rigidity forvarious applications. It may also be advantageous to incorporatealuminum wires to increase strength or mold ability. Introduction of PVCor other materials may be advantageous to reduce electricalconductivity, control audible properties during use or when cutting, oraffect other attributes. For example, the aluminum foil board may needto be cut into shapes (e.g., with a razor knife) while on a motionpicture or television production set during a shoot, and excessive noisecreated by cutting the material could adversely impact the production.

Such a product comprising aluminum foil or other lightweight fireresistant materials that can be self supporting (rigid) and can hold ashape or form can create a lightweight lighting accessory comprising afull or partial channel for channeling, reflecting, directing,enclosing, stopping or redirecting light from an illumination sourceused in television or motion picture filming or video. Such enclosure,reflector or accessory as described may be formed of one or more walls(boards) having two outer layers with a third (or more) layer(s)therebetween, wherein the outer layer(s) have a metallic(reflective/heat resistant) surface and the third or additional layersbetween provide structural support for the two outer layers.

In some applications, the foil board may be constructed in a form thatcan “roll up”. By providing ridges (or scores) along only one length itis possible to roll up the material for shipping or storage. Affixing(sandwiching) two or more pieces together with the ridges juxtaposedallows the construction of a rigid and flat “board ” when affixed but acompact rolled-up material when non affixed. The ability to roll up thefoil board material could also be advantageous in creating cylindricalshaped “snoots” for use to shape the light from a lighting instrument.

FIG. 9 is a diagram of a reinforced aluminum sheet as may be used in analuminum foil board in various embodiments. In FIG. 9, a pattern ofrolled aluminum wirelike ropes 905, each formed from rolled aluminumfoil, are spaced along an aluminum foil sheet 901 or other backing. Asecond aluminum foil sheet (not shown) may be placed on top of thealuminum wirelike ropes 905, forming a sandwich structure similar toFIG. 1A. For additional strength, another set of rolled aluminumwirelike ropes may be placed perpendicular to the ropes 905 shown inFIG. 9, thus forming a criss-cross of interlaced pattern.

FIG. 10 is a diagram of another embodiment as disclosed herein. In FIG.10, a pattern of air-filled aluminum bubbles 1007 are spaced inequidistant lines 1005 across an aluminum foil sheet 1001 to providestructural support. A second aluminum foil sheet (not shown) may beplaced on top of the air-filled aluminum bubbles 1007, forming asandwich structure similar to FIG. 1A.

In some embodiments, it may be desirable to have the back side of thealuminum foil board made of a different material than aluminum, e.g.,from a plastic laminate, an adhesive paper, poster board, or othermaterial. Also, in some cases it may be desirable to include additionalintervening layers of material in the interior of the aluminum foilboard, including thin cardboard, poster board, plastic or the like.

Many embodiments of a corrugated aluminum foil board as described hereinmay provide environmental benefits in addition to the otheraforementioned benefits. For example, the aluminum foil board may bemanufactured entirely or substantial part from recycled material, andmay also itself by entirely or substantially recyclable.

While preferred embodiments of the invention have been described herein,many variations are possible which remain within the concept and scopeof the invention. Such variations would become clear to one of ordinaryskill in the art after inspection of the specification and the drawings.The invention therefore is not to be restricted except within the spiritand scope of any appended claims.

1. An aluminum foil board product, comprising: a first sheet of aluminumfoil; a corrugated aluminum foil layer; a second sheet of material;wherein the corrugated aluminum foil layer is sandwiched between thefirst sheet of aluminum foil and the second sheet of material.
 2. Theproduct of claim 1, wherein said second sheet of material is aluminumfoil.
 3. The product of claim 1, having a reflective aluminum surface onone or more outer sides.
 4. The product of claim 1, having a darkenednon-reflective surface on one or more outer sides.
 5. The product ofclaim 1, having a variegated surface texture on one or more outer sides.6. The product of claim 1, having a surface color for modifying thecolor characteristics or quality of the reflected light.
 7. The productof claim 1, wherein the first sheet of aluminum foil, the corrugatedaluminum foil layer, and the second sheet of material collectively forma relatively rigid structure.
 8. The product of claim 1, wherein saidfirst sheet of aluminum foil comprises a plurality of textures orcolorized sections arranged in a repeating pattern.
 9. The product ofclaim 1, further comprising a second corrugated aluminum foil layer,stacked with the first corrugated aluminum foil layer such that thecorrugations of the first and second corrugated aluminum foil layers areat cross-angles to provide increased strength or rigidity.
 10. Theproduct of claim 1, further comprising metal wires between said firstsheet of aluminum material and second sheet of material forreinforcement.
 11. The product of claim 1, wherein the first sheet ofaluminum foil, the corrugated aluminum foil layer, and the second sheetof material collectively form a composite structure that is easily cutwith a razor knife.
 12. The product of claim 1, wherein the first sheetof aluminum foil, the corrugated aluminum foil layer, and the secondsheet of material collectively form a composite structure that is can berolled.
 13. The product of claim 1, further comprising a non-conductivematerial coating over the first sheet of aluminum foil or the secondsheet of material.
 14. The product of claim 1, wherein the first sheetof aluminum foil, the corrugated aluminum foil layer, and the secondsheet of material collectively form a composite structure that is bothwater resistant and fire resistant.
 15. A method for manufacturing analuminum foil board product, comprising the steps of: forming analuminum foil sheet into a corrugated aluminum foil layer having a frontside and a back side; affixing the front side of the corrugated aluminumfoil layer to a first sheet of aluminum foil; and affixing the back sideof the corrugated aluminum foil layer to a second sheet of material,thereby sandwiching the corrugated aluminum foil layer between the firstsheet of aluminum foil and the second sheet of material; whereby acomposite structure of increased strength and rigidity is formed. 16.The method of claim 15, wherein said second sheet of material isaluminum foil.
 17. The method of claim 15, further comprising: forming asecond aluminum foil sheet into a second corrugated aluminum foil layer;and stacking the second corrugated aluminum foil layer with the firstcorrugated aluminum foil layer such that the corrugations of the firstand second corrugated aluminum foil layers are at cross-angles toprovide increased strength or rigidity.
 18. The method of claim 15,wherein one or more of the outer sides of the composite structure arehighly reflective.
 19. A lighting accessory, comprising: a housing forchanneling or directing illumination from a lighting fixture, saidhousing having one or more reflective surfaces; said housing comprisinga plurality of panels, at least one of said panels constructed from afirst sheet of aluminum foil, a corrugated aluminum foil layer, and asecond sheet of material, wherein the corrugated aluminum foil layer issandwiched between the first sheet of aluminum foil and the second sheetof material.